Download - Pneumatic Control Valve for Steam COSPECT PN-COS-16

172-65588A-02 (PN-COS Pneumatic Control Valve) 14 January 2021

Manufacturer

881 Nagasuna, Noguchi, Kakogawa, Hyogo, 675-8511, Japan

Tel: [81]-(0)79-422-1122 Fax: [81]-(0)79-422-0112

Copyright © 2021 by TLV Co., Ltd. All rights reserved

Pneumatic Control Valve for Steam

COSPECT

PN-COS-16

172-65588A-02 (PN-COS Pneumatic Control Valve) 14 Jan 2021

1

Contents Introduction ........................................................................ 1

Safety Considerations ........................................................ 2

Specifications ..................................................................... 4

Acceptable Operating Range ............................................. 4

Correct Usage of the PN-COS-16 ...................................... 5

Configuration ...................................................................... 7

Installation .......................................................................... 8

Operation ......................................................................... 14

Maintenance ..................................................................... 17

Disassembly ..................................................................... 18

Reassembly ..................................................................... 22

Troubleshooting ............................................................... 23

TLV EXPRESS LIMITED WARRANTY ............................ 26

Introduction Thank you for purchasing the TLV pneumatic control valve for steam, model PN-COS-16.

This product has been thoroughly inspected before being shipped from the factory. When the product is delivered, before doing anything else, check the specifications and external appearance to make sure nothing is out of the ordinary. Also be sure to read this manual carefully before use and follow the instructions to be sure of using the product properly.

The TLV pneumatic control valve for steam, model PN-COS-16 is a new type of pneumatic control valve for steam that utilizes the structure of the COSPECT series pilot operated pressure reducing valve, which is our unique product. Steam-using equipment can achieve its intended efficiency only if the steam being used is very dry. Using steam in which matter such as condensate, scale, types of grease or air is entrained can not only result in problems with the steam-using equipment and in lowered productivity, but can also lead to shortened service life for and malfunction of the control valves.

The TLV pneumatic control valve for steam, model PN-COS-16, has a built-in cyclone separator, screen, and steam trap that eliminates these problems and makes possible the supply of very dry steam at a stable pressure.

The PN-COS-16 can operate automatically and provide accurate pressure control and temperature control when combined with the TLV SC-F70 digital indicator controller or a general-purpose controller. (However, for process temperature control, the desired process temperature must be controllable by a secondary pressure within the adjustable pressure range of the PN-COS-16.) Additionally, manual remote setting or 2 point pressure switching as a pressure reducing valve is possible by combination with an air regulator (with relief function).

If detailed instructions for special order specifications or options not contained in this manual are required, please contact TLV for full details.

This instruction manual is intended for use with the model(s) listed on the front cover. It is needed not only for installation, but also for subsequent maintenance, disassembly/reassembly and troubleshooting. Please keep it in a safe place for future reference.


2

Safety Considerations Read this section carefully before use and be sure to follow the instructions.

Installation, inspection, maintenance, repairs, disassembly, adjustment and valve

opening/closing should be carried out only by trained maintenance personnel.

The precautions listed in this manual are designed to ensure safety and prevent

equipment damage and personal injury. For situations that may occur as a result

of erroneous handling, three different types of cautionary items are used to

indicate the degree of urgency and the scale of potential damage and danger:

DANGER, WARNING and CAUTION.

The three types of cautionary items above are very important for safety: be sure to

observe all of them as they relate to installation, use, maintenance and repair.

Furthermore, TLV accepts no responsibility for any accidents or damage occurring

as a result of failure to observe these precautions.

Symbols

Indicates a DANGER, WARNING or CAUTION item.

DANGER Indicates an urgent situation which poses a threat of death or serious injury

WARNING Indicates that there is a potential threat of death or serious injury

CAUTION Indicates that there is a possibility of injury or equipment / product damage

WARNING

NEVER apply direct heat to the float.

The float may explode due to increased internal pressure,

causing accidents leading to serious injury or damage to property

and equipment.

CAUTION

Install properly and DO NOT use this product outside the

recommended operating pressure, temperature and other

specification ranges.

Improper use may result in such hazards as damage to the

product or malfunctions that may lead to serious accidents. Local

regulations may restrict the use of this product to below the

conditions quoted.

DO NOT use the product in excess of the maximum

operating pressure differential.

Such use could make discharge through the steam trap

impossible (blocked).

Use hoisting equipment for heavy objects (weighing

approximately 20 kg (44 lb) or more).

Failure to do so may result in back strain or other injury if the

object should fall.

Take measures to prevent people from coming into direct

contact with product outlets.

Failure to do so may result in burns or other injury from the

discharge of fluids.

Continued on the next page


3

CAUTION

When disassembling or removing the product, wait until the

internal pressure equals atmospheric pressure and the

surface of the product has cooled to room temperature.

Disassembling or removing the product when it is hot or under

pressure may lead to discharge of fluids, causing burns, other

injuries or damage.

Be sure to use only the recommended components when

repairing the product, and NEVER attempt to modify the

product in any way.

Failure to observe these precautions may result in damage to the

product and burns or other injury due to malfunction or the

discharge of fluids.

Do not use excessive force when connecting threaded pipes

to the product.

Over-tightening may cause breakage leading to fluid discharge,

which may cause burns or other injury.

Use only under conditions in which no freeze-up will occur.

Freezing may damage the product, leading to fluid discharge,

which may cause burns or other injury.

Use only under conditions in which no water hammer will

occur.

The impact of water hammer may damage the product, leading

to fluid discharge, which may cause burns or other injury.

Make sure the power supply is OFF before carrying out

work on the wiring or inspections involving disassembly.

If such work is carried out with the power on, there is a danger

that equipment may malfunction or electric shock may occur,

leading to injury or other accidents.

Make sure that wiring work requiring a special license is

carried out by qualified personnel.

If carried out by unqualified personnel, overheating or short circuits

leading to injury, fires, damage or other accidents may occur.

When using this product, NEVER stand close to, or leave

tools anywhere near moving parts, such as the shaft.

Contact with moving parts or objects becoming caught in moving

parts could lead to injury or damage or other accidents.


4

Specifications

Install properly and DO NOT use this product outside the recommended

operating pressure, temperature and other specification ranges.

Improper use may result in such hazards as damage to the product or

malfunctions which may lead to serious accidents. Local regulations

may restrict the use of this product to below the conditions quoted.

CAUTION

DO NOT use the product in excess of the maximum operating pressure

differential; such use could make discharge through the steam trap

impossible (blocked).

CAUTION

Use only under conditions in which no freeze-up will occur. Freezing

may damage the product, leading to fluid discharge, which may cause

burns or other injury. CAUTION

Refer to the product nameplate for detailed specifications.

Model

Nominal Diameter

Maximum Operating Temperature

Valve No.*

Secondary Pressure Adjustable Range

Primary PressureRange

Production Lot No.

* Valve No. is displayed for products with options. This item is omitted from the nameplate when there are no options.

<Required utilities> Adjustment Section (Drive Section)

Motive Air

Maximum Pressure 1.6 MPaG (250 psig)

Required Air Pressure [Desired secondary pressure + 0.1] MPaG or higher [Desired secondary pressure + 15] psig or higher

Air Connecting Port Rc(PT), BSP or NPT 1/4"

Air Quality Oil-free air, filtered to 5 m

(1 MPa = 10.197 kg/cm2)

<CV Value> Size: mm (in) 15 (1/2) 20 (3/4) 25 (1) 40 (11/2) 50 (2)

CV (US) 3.8 6.9 11.1 24.0 37.2

CV (UK) 3.2 5.7 9.2 20.0 31.0

Kvs (DIN) 3.3 5.9 9.5 20.6 31.9

Acceptable Operating Range

Model PN-COS-16

Primary Pressure Range* 0.2 –1.6 MPaG (30 – 250 psig)

Adjustable Pressure Range (All conditions must be met)

Within 10 – 84% of the primary pressure

(Minimum adjustable pressure of 0.03 MPaG (5 psig)

Pressure differential between 0.07 to 0.85 MPa (10 to 120 psi)

Minimum Adjustable Flow Rate 5% of rated flow rate

(1 MPa = 10.197 kg/cm2)

*For process temperature control, the desired process temperature must be controllable by a secondary pressure within the adjustable pressure range of the PN-COS-16.


5

Correct Usage of the PN-COS-16






CAUTION

1. The PN-COS-16 should be operated only within its specifications.

2. Installing an ON / OFF Valve (Solenoid Valve or Motorized Valve)

PN-COSMotorized

Valve

Inlet side

PN-COS

SolenoidValve

Outlet side

If an on-off valve, such as a motorized valve, is required to stop supply of steam to the steam-using equipment, install it at the inlet side of the PN-COS-16. If a solenoid valve is installed at the outlet of the PN-COS-16, its opening and closing will cause heavy chattering and may lead to damage of the piston and main valve. (When the on-off valve opens, the secondary pressure of the PN-COS-16 changes from zero to the set pressure. Passing through an area of the reducing ratio of less than 10:1, where adjustment is impossible, chattering occurs momentarily.) To save energy, it is recommended to install the on-off valve as near to the boiler as possible.

NOTE: To prevent water hammer, it is recommended that a slow-acting motorized on-off valve be used. In particular, if a fast-acting on-off solenoid valve is used for frequent temperature control, the potential water hammer effect can damage the steam-using equipment and the PN-COS-16.

3. Installing a Control Valve

ControlValve

Equipment

PN-COS

SafetyValve

Equipment

PN-COS

SafetyValve

ControlValve

A control valve installed between the PN-COS-16 and the steam-using equipment (downstream of the PN-COS-16) for controlling equipment temperature may raise the pressure between the PN-COS-16 and the control valve when the control valve is closed, depending on the spatial relationship. A safety valve should be installed downstream of the control valve.

NOTE: When installing a safety valve to protect the steam-using equipment, be sure to install it on the steam-using equipment or directly before the inlet of the steam-using equipment. If the safety valve is installed on the outlet side of the PN-COS-16 between the PN-COS-16 and a control valve, an eventual pressure rise could activate the safety valve.


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4. Precautions for the Installation of Additional Fittings Before or After the PN-COS-16

In order to ensure stable steam flow, the piping upstream and downstream of the PN-COS-16 must be straight runs. If the PN-COS-16 is installed either directly before or after an elbow or control valve, unevenness in steam flow may result in chattering and unstable pressure. To ensure stable steam flow, it is recommended that the PN-COS-16 be installed on straight runs of piping, as illustrated below.

1) Inlet (primary side) of the PN-COS-16 (d = pipe diameter) Maintain a straight piping run of

10 d or more when a manual valve, a strainer or an elbow, etc. is installed. (Example: if nominal size is 25 mm (1 in), have 250 mm (10 in) or more)

PN-COSValve, strainer,

elbow, etc.

10 d or more

PN-COSValve, strainer,

elbow, etc.

Less than10 d

Maintain a straight piping run of

30 d or more when an automated valve (on-off valve) is installed. (Example: if nominal size is 25 mm (1 in), have 750 mm (30 in) or more)

PN-COSMotorized

Valve

30 d or more

PN-COSMotorized

Valve

Less than30 d

Maintain a straight piping run of

30 d or more when a pressure reducing valve is installed. (Two-stage pressure reduction) (Example: if nominal size is 25 mm (1 in), have 750 mm (30 in) or more)

PN-COS

Pressure Reducing

Valve

30 d or more

PN-COS

Pressure Reducing

Valve

Less than30 d

2) Outlet (secondary side) of the PN-COS-16 Maintain a straight piping run

of 15 d or more when a manual valve, a strainer or an elbow, etc. is installed. (Example: if nominal size is 25 mm (1 in), have 375 mm (15 in) or more)

PN-COS Valve, strainer,

elbow, etc.

15 d or more

PN-COS Valve, strainer,

elbow, etc.

Less than 15 d

Maintain a straight piping run

of 30 d or more when a safety valve is installed. (Example: if nominal size is 25 mm (1 in), have 750 mm (30 in) or more)

PN-COS Safety Valve

30 d or more

PN-COS Safety Valve

Less than 30 d

Maintain a straight piping run

of 30 d or more when a control valve or an automated valve (on-off valve) is installed. (Example: if nominal size is 25 mm (1 in), have 750 mm (30 in) or more)

PN-COS

30 d or more

Control or Automated

Valve

PN-COS

Less than 30 d

Control or Automated

Valve


7

Configuration

15 – 50 mm (1/2 – 2 in)

10 mm(3/8 in)

8 mm (1/4 in)Motive AirPort

15 mm (1/2 in)Condensate

Discharge Port

*

*North American model does not equip this plug.

No. Name

1 Main Body

2 Trap Body

3 Trap Cover

4 Separator

5 Float

6 Float Cover

7 Guide Pin

8 Trap Valve Seat

9 Trap Valve Seat Gasket

10 Gasket (Trap Body/Trap Cover)

11 Wave Spring

12 Gasket (Main Body/Trap Body)

13 Separator Screen

14 Main Valve Seat

15 Main Valve Seat Gasket

16 Main Valve

17 Main Valve Holder

18 Steel Ball

19 Main Valve Spring

20 Piston

21 Piston Ring

22 Tension Ring

23 Cylinder

24 Gasket (Pilot Body/Main Body)

25 Connecting Tube

26 Pilot Screen

27 Pilot Screen Holder

28 Pilot Screen Holder Gasket

29 Pilot Valve Spring

30 Pilot Body

31 Piston Guide

32 Sleeve

33 Pilot Valve

34 Pilot Valve Seat

35 Pilot Valve Seat Gasket

36 Diaphragm

37 Diaphragm Gasket

38 Diaphragm Support

39 Spring Housing

40 Coil Spring

41 Spring Retainer

42 Adjustment Screw

43 Packing Retainer

44 Spanner Cap

45 Hex Bolt (Trap Body/Trap Cover)

46 Hex Bolt (Main Body/Trap Body)

47 Hex Bolt (Pilot Body/Main Body)

48 Hex Bolt (Spring Housing/Pilot Body)

49 Bushing

50 Plug – Sensing Line Port*

51 Float Cover Bolt

52 Spring Washer

53 Cylinder Gasket

54 Nameplate

55 C-ring

56 Gland Packing

57 O-ring


8

Installation






CAUTION

Use hoisting equipment for heavy objects (weighing approximately

20 kg (44 lb) or more). Failure to do so may result in back strain or other

injury if the object should fall. CAUTION

Take measures to prevent people from coming into direct contact with

product outlets. Failure to do so may result in burns or other injury from

the discharge of fluids. CAUTION

Installation, inspection, maintenance, repairs, disassembly, adjustment and valve opening/closing should be carried out only by trained maintenance personnel.

Installation Environment

Avoid installation in the following types of environments:

Locations with ambient temperatures above 50 °C (122 °F) or below 0 °C (32 °F)*

Locations with ambient humidity above 90% RH and below 10% RH

Locations where corrosive gas is generated

Locations with heavy vibration or shock

Locations with high inductive interference or other factors that would have a

harmful effect on electrical circuitry*

*When the PN-COS-16 is used with electrical equipment such as an electro-pneumatic

transducer, controller, etc.

1. Blowdown PN-COSOpen

Closed Closed

Blowdown with the Bypass Valve

Before installing the PN-COS-16 unit, be sure to blow down all piping thoroughly. If this is not possible, perform a blowdown using the bypass valve.

Blowdown is especially important for newly installed piping or after the system has been shut down for a long period of time.

2. Removing Seal and Cap

① ②

③

Before installation, be sure to remove all protective seals and caps. (Found in 3 locations, on the product inlet and outlets.)

3. Installation Angle

15 1515 15

10101010

Install the PN-COS-16 vertically, so that the arrow mark on the body points horizontally in the direction of steam flow.

Allowable inclination is 10 degrees in the fore-aft direction and 15 degrees in the plane perpendicular to the steam flow line.


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4. Spacer Installation

If spacing adjustment is necessary to accommodate installation, install a spacer on the outlet flange. The spacer should consist of a spacer, gaskets, bolts and nuts. Fit gaskets to both sides of the spacer between the PN-COS-16 outlet and the pipe flange. Fasten with bolts and nuts.

Correct spacer location

Incorrect spacer

location

5. Piping Support

Install the PN-COS-16, paying attention to avoid excessive load, bending and vibration. Support the inlet and outlet pipes securely.

6. Maintenance Space

200(8)

200 (8)

150(6)

100 (4)

150(6)

200(8)

Leave sufficient space for maintenance, inspection and repair.

(Unit: mm (in))

7. Trap Outlet Pipe

Small Hole

For ease of maintenance, installation of a union connection is recommended for the trap outlet pipe. Connect the outlet pipe to a condensate return line, or extend it to a trench. In the case of the latter, make sure the end of the pipe is above the waterline. (Dirt and water may be sucked up by the vacuum formed during trap closure and system shutdown.)


10

8. Pressure Sensor Installation (for pressure control) The length of piping between the PN-COS-16 and the pressure sensor should be no more than 5 m (17 ft). If the piping distance is too great, pressure loss and delay of pressure change along this distance will increase, resulting in steam flow rate fluctuations.

PN-COSPressureGauge

PressureSensor

>>

>

>>

>

>

>

>

>

Straight pipe

Straight pipe

15 d or more

5 d or more

Distance of5 m (17 ft) or less

Steam fluctuations at the pressure sensor may impair the stability of the pressure control. Ensure a straight piping run of at least 15 d upstream and 5 d downstream from the pressure sensor.

9. Blowdown Valve (requires an optional plug)

In an environment of heavy dirt or scale, or when the steam-using equipment is used only periodically, such as for room heating equipment, be sure to use a

blowdown valve. 1) Remove the plug (option) from the main body. 2) Install the blowdown valve. 3) Open the blowdown valve and blow any residual dirt

and scale off of the screen. 4) Periodically activate the blowdown valve to keep the

system free of dirt and scale.

Remove the 10 mm (3/8 in) plug (optional) and install the blowdown valve

10. Piping Size

If the secondary steam flow velocity is expected to be more than 30 m/s (100 ft/s), install a diffuser in order to keep the flow velocity below 30 m/s (100 ft/s). If the distance between the PN-COS-16 and the steam-using equipment is great, a possible drop in pressure should be taken into consideration when selecting the piping size.

In addition, when installing the strainer, the strainer screen should be either at the 3 o’clock or 9 o’clock position to prevent condensate accumulation.

PN-COS

Diffuser

Straight-run piping lengths (d = pipe diameter):

PN-COS

Diffuser

Straight-run piping lengths (d = pipe diameter):Upstream = 10 d or more; Downstream = 15 d or more

PN-COS

Diffuser

Straight-run piping lengths (d = pipe diameter):

PN-COS

Diffuser

Straight-run piping lengths (d = pipe diameter):Upstream = 10 d or more; Downstream = 15 d or more

PN-COSPN-COS


11

11. Two-stage Pressure Reduction

Whenever the pressure cannot be reduced to the desired level with a single PN-COS-16 due to operating range limitations, such as when the reduction ratio is greater than 10:1, the pressure reducing valve should be installed at the primary side.

PN-COS

PressureGauge

PressureGauge

PressureGauge

BypassValve

PrimarySide

Shut-offValve

Shut-offValve

PressureReducing

Valve

BypassValve

Shut-offValve

Shut-offValve

Safety Valve(Relief Valve)

PN-COS

PressureGauge

PressureGauge

BypassValve

Shut-offValve

Shut-offValve

Safety Valve(Relief Valve)

PrimarySide

12. Accessories

Always install a shut-off valve, pressure gauge and bypass line at both inlet and outlet. Ball valves, which will not retain condensate, are recommended for inlet and outlet shut-off valves. The bypass pipe should be at least 1/2 of the size of the inlet (primary side) pipe.

PN-COS

Ball Valve Ball Valve

GlobeValve

PressureGauge

PressureGauge

PN-COSPN-COS

13. External secondary pressure-sensing line (when required)

North American Models:

North American Models are factory prepared for external sensing. An external sensing line MUST be installed. DO NOT SUPPLY STEAM until all piping and a 10 mm (3/8 in) secondary pressure sensing line with a slightly falling pitch have been properly installed. Install a shutoff valve in the pressure sensing line for maintenance purposes.

Keep the shutoff valve open at all times during operation. If the shutoff

valve is closed,PN-COS-16 will fully open and PRIMARY PRESSURE WILL BE

SUPPLIED TO THE EQUIPMENT (see “Piping Example” on next page).

CAUTION

Non-North American Models:

Factory-standard PN-COS-16 employs an internal secondary pressure-sensing channel built into the body, saving the need to install an external pressure-sensing line to detect the secondary pressure. Installation of an external secondary pressure-sensing line involves closing the internal pressure-sensing channel and installing a line from the sensing line port to the point where pressure should be controlled. This can increase stability of pressure control where steam loss in secondary piping and flow rate fluctuation is


12

high. In addition, the rated flow rate will be greater than an internal pressure-sensing channel under the operational pressure reduction ratio of 2:1 or more.

Installation procedure 1) Loosen and remove the bolts that attach the pilot body to the main body and

remove the pilot body.

2) Install the blind pin (optional) by first removing the connecting tube from the main body or pilot cover and then substituting the blind pin.

3) Re-install the pilot body and fasten the bolts evenly to the proper torque (see the torque chart in the “Reassembly” section).

4) Remove the plug from the secondary pressure sensing line port and connect the secondary pressure sensing line.

5) Install the secondary pressure sensing line with a slightly falling pitch. The end of the secondary pressure sensing line should be connected to the place on the main piping where the pressure is to be sensed (see the piping example on the next page). A shut-off valve and union should be installed in the secondary pressure sensing line.

Pilot Body

Body

Secondary Pressure Sensing Line Port(Rc(PT)3/8, BSP3/8 or NPT 3/8)

Hex Bolt

Secondary PressureSensing Port

Connecting Tube

Replace the factory-installed connecting tube (has a hole) with the optional blind pin (has no hole).

Blind PinConnecting

Tube

Piping Example:

1 m (3.3 ft) or 15 d, whichever is larger

Steam-using EquipmentSteam-using Equipment

PN-COS

15 dor more

< ><>

10 mm (3/8 in) Pressure Sensing Line (with a slightly falling pitch towards the sensing point)

BallValve


13

14. Internal sensing for North American models All models except North American models are factory prepared for internal sensing. When internal pressure sensing is required for North American models, please contact the nearest TLV representative to request both a connecting tube, which must be installed in place of the blind pin, and a threaded secondary pressure sensing plug. Follow the connecting tube installation procedure shown below: 1) Loosen and remove the four (4) bolts that attach

the pilot body to the main body and remove the pilot body.

2) Install the connecting tube by first removing the blind pin from the secondary side of the main body and then substituting the connecting tube.

3) Re-install the pilot body and fasten the four (4) bolts evenly. See the torque chart in the “Reassembly” section in this manual for torque requirements of these bolts.

4) If a secondary pressure sensing pipe has previously been installed, remove it and be certain to install the threaded secondary pressure sensing line plug in its place.

NOTE: When 15 mm (1/2 in) or 20 mm (3/4 in) PN-COS-16 is used below 0.3 MPaG (45 psig) and 0.1 MPaG (15 psig) respectively, and below 50% of primary pressure, internal sensing may provide decreased capacity (Rated Flow Rate) compared to external sensing. Verify the capacity before switching to internal sensing.

Blind Pin Connecting Tube


14

Operation

When using this product, NEVER stand close to, or leave tools anywhere

near moving parts, such as the shaft. Contact with moving parts or objects

becoming caught in moving parts could lead to injury or damage or other

accidents.

CAUTION

Procedure

The system configuration examples (diagrams) shown in this section are for

explanation purposes only, and are not intended as installation designs.)

Automatic Control

<Example: Pressure control system (as control valve)>

PressureTransmitter

ControllerAir

Regulator

Electro-PneumaticTransducer

PN-COS-16

<Example: Temperature control (as control valve)>

ControllerAir

Regulator

Electro-PneumaticTransducer

PN-COS-16

Automatic control is possible when the PN-COS-16 is used with a controller. However, an electro-pneumatic transducer is required in order to control the air for operation. The wiring, etc. should be carried out according to the instruction manual for the controller, the electro-pneumatic transducer, or related devices.

Please set the position of the adjustment screw on the PN-COS-16 according to the steps shown in the “Setting the pressure with the adjustment screw”.

In addition, for process temperature control, the secondary pressure of the PN-COS-16 needs to be within the pressure adjustable range at the time of normal operation.


15

Manual Control

<Example: Manual remote operation (as pressure reducing valve)>

(installed in a

high position)

AirRegulator

(with relief)

PN-COS-16

When operating the PN-COS-16 remotely by manual operation, an air regulator (with relief function) that adjusts motive air pressure is required. Adjust the set pressure with the air regulator while checking the pressure gauge on the secondary side.

Please set the position of the adjustment screw according to the steps shown in the "Setting the pressure with an adjustment screw" on the following page.

<Example: 2 point pressure switching (as pressure reducing valve)>

ON/OFFSwitch

3 WaySolenoid Valve

Air Regulator(with relief)

PN-COS-16

Pressure at the secondary side can be switched manually between 2 points with an ON/OFF switch. To do so, an air regulator (with relief function), which adjusts the motive air, a 3 way solenoid valve, and an ON/OFF switch are required. Pressure setting at the higher pressure side should be adjusted with the motive air by checking the pressure gauge at the secondary side. For pressure setting at the lower pressure side, follow the steps in the "Setting the pressure with the adjustment screw" below.

Setting the pressure with the adjustment screw

Other than setting the secondary steam pressure of PN-COS-16

using air pressure, it can be set by the adjustment screw.

・ To Maintain minimum required pressure by adjustment screw

Set the steam pressure at the secondary pressure side to a minimum required pressure using the adjustment screw.

・ When setting the pressure using only motive air

Loosen the adjustment screw until there is no load on the coil spring. The valve should be closed once there is no motive air.

AdjustmentScrew


16

<Adjustment>

1. It is necessary to blow down all pipe lines thoroughly. The blowdown is especially important if the line is new or has been shut down for a long period of time. Take particular care to ensure that matter such as condensate and dirt does not remain inside the steam-using equipment. (Stay clear of any pressurized blow-out from the safety valve.)

2. Make sure that the shut-off valve and the bypass valve located upstream and downstream of the PN-COS-16 are completely closed.

3. Remove the spanner cap and turn the adjustment screw counterclockwise to reduce tension on the coil spring. NOTE: Do not pull up the adjustment screw forcibly once the adjustment screw has

reached the point at which it stops. The internal stopper (C-ring) may break.

4. Slowly, fully open the shut-off valve at the inlet of the PN-COS-16. Allow sufficient time for condensate remaining at the inlet of the PN-COS-16 to be discharged through the built-in steam trap.

5. Slightly open the shut-off valve at the outlet of the PN-COS-16.

6. Turn the adjustment screw clockwise until the desired outlet pressure is obtained. Wait several minutes.

Tighten the adjustment screw to increase pressure

Loosen the adjustment screw to decrease pressure

Clockwise Counterclockwise

7. Slowly, fully open the shut-off valve at the secondary side of the PN-COS-16. After

setup, put the spanner cap back on.

8. When shutting down the system, always close the shut-off valve at the outlet first

and then the inlet.


17

Maintenance

Take measures to prevent people from coming into direct contact with

product outlets. Failure to do so may result in burns or other injury from

the discharge of fluids. CAUTION

Be sure to use only the recommended components when repairing the

product, and NEVER attempt to modify the product in any way. Failure to

observe these precautions may result in damage to the product or burns

or other injury due to malfunction or the discharge of fluids.

CAUTION

Make sure the external power supply switch is OFF before carrying out

work on the wiring or inspections involving disassembly.

If such work is carried out with the power on, there is a danger that

equipment may malfunction or electric shock may occur, leading to

injury or other accidents.

CAUTION

Operational Check

To ensure long service life of the PN-COS-16, the following inspection and maintenance should be performed regularly.

Part Inspection and Maintenance Frequency

Screens

(Separator, Pilot)

Disassemble and clean annually.

If there is substantial blockage, install a strainer

(approximately 60 mesh) ahead of the PN-COS-16.

Main Valve, Main Valve

Seat, Pilot Valve and Pilot

Valve Seat

Replace after approximately 15,000 hours.

If there is chattering or dirt, premature wear may result.

Piston Ring Replace after approximately 8,000 hours.

If there is chattering or if scale build-up is severe,

premature wear may result.

Piston Replace after approximately 30,000 hours.

If hunting or chattering takes place, premature wear may

result.

Trap Valve Seat Replace after approximately 40,000 hours.

If scale build-up is severe, blockage may occur in a short

period of time.

Diaphragm Replace after approximately 30,000 hours.

If hunting or chattering takes place, cracks or fatigue may

develop in a short period of time.


18

Disassembly

NEVER apply direct heat to the float. The float may explode due to

increased internal pressure, causing accidents leading to serious injury

or damage to property and equipment. WARNING

Use hoisting equipment for heavy objects (weighing approximately

20 kg (44 lb) or more). Failure to do so may result in back strain or other

injury if the object should fall. CAUTION

When disassembling or removing the product, wait until the internal

pressure equals atmospheric pressure and the surface of the product

has cooled to room temperature. Disassembling or removing the

product when it is hot or under pressure may lead to discharge of fluids,

causing burns, other injuries or damage.

CAUTION

It is a recommended practice to dismantle and inspect the PN-COS-16 once a year for preventive maintenance purposes. It is especially important to perform an inspection immediately after the initial run of a new line or before or after equipment such as a heater is out of service for a long period of time. (Installation, inspection, maintenance, repairs, disassembly, adjustment and valve opening/closing should be carried out only by trained maintenance personnel.)

Remove all steam from the piping (both upstream and downstream). Stop supplying motive air to the PN-COS-16. Remove the spanner cap, and then pull up the adjustment screw until there is no load on the coil spring. Wait for the body to cool before attempting to remove the PN-COS-16 from the line as it may be heated with the residual heat of steam. Then remove the inlet and outlet flange retaining bolts and nuts to permit removal of the PN-COS-16. Secure the PN-COS-16 in a vise to perform the inspection.

Disassembling the Adjustment Section (Drive Section)

Make sure that the position of the adjustment screw is such that no load is applied to the coil spring. Remove the hex bolts and then take off the spring housing. Remove the C-ring with an appropriate tool to remove the adjustment screw. Remove the adjustment screw by loosening it. Then remove the packing retainer by turning it counterclockwise.

Spanner Cap

Adjustment Screw

Spring Housing

Ball

Hex Bolt

O-ring

Packing Retainer

Gland Packing

C-ring

Spring Retainer

Coil Spring

Diaphragm Support

NOTE: Make sure that there are no scratches or wear on the internal parts. Do not reuse the

O-ring and the gland packing.


19

Disassembling the Pilot Section

The diaphragm is removed by utilizing the notch in the pilot body. Loosen the pilot valve seat with a box wrench and remove it. Lift the pilot valve spring up and out with a pair of tweezers. Then loosen and remove the pilot screen holder to remove the pilot screen.

Check for any fault on the seating surface of the pilot valve, flaws on the gaskets, and clogging of the pilot screen.

Check for deformation, corrosion or faults on the diaphragm. The diaphragm should be convex (open downward), with the printed UP mark on the top.

Diaphragm

Pilot Valve Seat(with Gasket)

Pilot Valve Stem

Pilot Valve

Pilot Valve Spring

Hex Bolt

Pilot Body

UpperPilot Body

Gasket

Notch

Pilot Screen

Pilot Screen Holder(with Gasket)

Plug

Disassembling the Piston Section

Take the pilot body off after removing the hex bolts. During this process, pay attention

not to lose the connecting tubes (2 pcs).

Remove the piston guide, piston and cylinder from the main body. Then remove the

piston rings and the tension rings from the piston. Do not apply too much force when

removing the piston rings and tension rings.

Check the interior of the cylinder, the exterior of the piston rings, the small hole on

the piston and the cylinder gasket for any fault or abnormality.

Piston Guide

Piston

Connecting Tube

Piston RingTension Ring

Cylinder

Cylinder Gasket

Lower PilotBody Gasket

Main Body


20

Disassembling the Separator / Main Valve Section

Turn the PN-COS-16 upside down for easy dismantling of the separator and main

valve. Loosen the hex bolts and remove the trap body. Be careful, as the separator

may drop off when the PN-COS-16 is returned to the normal attitude.

Removal of the separator and pressed-in sleeve permits removal of the main valve,

main valve holder, main valve spring and separator screen.

Loosen the main valve seat with a socket wrench and remove it from the main body.

Check for damage on the seating surfaces of the main valve and main valve seat,

gaskets, and sliding surfaces of each part, and for clogging of the separator screen.

Wave Spring

Main Body

Main Valve Seat

Main Valve

Main Valve Holder

Main Valve Spring

Separator Screen

Sleeve

Separator

Trap Body

Gasket

HexBolt

Main Valve SeatGasket

Disassembling the Steam Trap Section

Loosen the hex bolts (for the trap cover)

and remove the trap cover. Be careful,

as hot condensate may splash out.

Remove the hex bolts (for the float

cover) and remove the float cover to

reveal the float. Remove the float, then

loosen the trap valve seat with a socket

wrench and remove it.

Check to determine that there is no

deformation of the float, abnormality in

the trap valve seat or dirt

accumulation in the trap cover.

Hex Bolt

Spring Washer

Trap Cover

Hex Bolt

Float

GasketTrap Valve Seat

Trap Valve SeatGasket

Hex Bolt

Spring Washer


21

Cleaning

After inspection and removal of any abnormality, clean and reassemble the parts. The

following parts will require cleaning before reassembly: Trap Cover Piston Float Piston Ring Trap Valve Seat Cylinder Pilot Screen Separator Screen Main Valve Seat Pilot Valve Main Valve Main Valve Holder

Pilot Valve Seat

It is permissible to clean using water, however cleaning with a mild detergent is recommended for more effective cleaning. (Coat threaded position with anti-seize after cleaning.)

Exploded View

Adjustment Section

(Drive Section)

Pilot Section

Piston Section

Separator / Main Valve Section

Steam Trap Section

NOTE: Configuration of each part varies depending on nominal size.


22

Reassembly Assemble the unit using the same procedure as used for disassebling it; but in

reverse order. Observe the following precautions:

1. The PTFE gaskets may be re-used if free from fault, crushing or deformation.

2. Apply anti-seize to the threaded portion of screws and bolts and adjustment screw. Apply a small amount of anti-seize to the threads of the main valve seat, pilot valve seat and screen holder to ensure it does not come into contact with other parts.

3. Fasten the bolts one at a time in an alternating diagonal pattern to provide uniform seating.

4. After the assembly, make sure that the piston and the pilot valve operate smoothly without binding.

1) Fit the piston ring to the outside of the

tension ring.

2) The ring gaps should be opposite each

other.

5. Standard fastening torque and the distance across flats for the tools to be used

are as follows:

Part

PN-COS-16

Connection Size

Distance

Across Flats Tightening Torque

(mm) (in) (mm) (in) (N·m) (lbf·ft)

Bolts (Spring Housing/ Pilot Body)

15 – 50 17 (21/32) 40 (29)

Pilot Valve Seat 15 – 50 19 (3/4) 70 (51)

Pilot Screen Holder

15 – 50 24 (15/16) 40 (29)

Hex Bolts (Pilot body/ Main Body)

15 – 40 (1/2 – 11/2) 17 (21/32) 60 (44)

50 (2) 19 (3/4) 70 (51)

Hex Bolts (Main Body/ Trap Body and Trap body/ Trap Cover)

15 – 40 (1/2 – 11/2) 17 (21/32) 60 (44)

50 (2) 19 (3/4) 70 (51)

Main Valve Seat 15, 20 (1/2, 3/4) 36 (17/16) 100 (73)

25 (1) 41 (15/8) 125 (92)

40 (11/2) 60 (23/8) 250 (185)

50 (2) 70 (23/4) 300 (220)

Hex Bolt (Float Cover)

15, 20 (1/2, 3/4) 8 (5/16) 7 (5)

25, 40 (1, 11/2) 10 (3/8) 10 (7)

50 (2) 13 (1/2) 20 (15)

Trap Valve Seat 15, 20 (1/2, 3/4) 11 (7/16) 10 (7)

25, 40 (1, 11/2) 13 (1/2) 15 (11)

50 (2) 17 (21/32) 40 (29)

(1 Nm 10 kgcm)

NOTE: -If a torque greater than that recommended is applied, the body or components may be

damaged.

-Coat all threaded portions with anti-seize.

-If drawings or other special documentation were supplied for the product, any torque

given there takes precedence over values shown here.


23

Troubleshooting

NEVER apply direct heat to the float. The float may explode due to

increased internal pressure, causing accidents leading to serious injury

or damage to property and equipment. WARNING

When disassembling or removing the product, wait until the internal

pressure equals atmospheric pressure and the surface of the product

has cooled to room temperature. Disassembling or removing the

product when it is hot or under pressure may lead to discharge of fluids,

causing burns, other injuries or damage.

CAUTION

When using this product, NEVER stand close to, or leave tools anywhere

near moving parts, such as the shaft. Contact with moving parts or objects

becoming caught in moving parts could lead to injury or damage or other

accidents.

CAUTION

This product is shipped after stringent checks and inspection and should perform its

intended function for a long period of time without failure. However, should there be

any problem encountered in the operation of the PN-COS-16, consult the

troubleshooting guide below.

Trouble could occur in the drive section, pressure-reducing section (including

separator and trap sections), or the controller used together with the PN-COS-16.

The location where the trouble has occured should be identified first.

<Diagnosis of malfunctions in the pressure-reducing section>

Problems are classified as follows: 1. The secondary pressure does not increase. 2. The secondary pressure cannot be adjusted or increases abnormally. 3. Hunting (fluctuation of the secondary pressure) occurs. 4. Chattering (a heavy mechanical noise) occurs. 5. Abnormal noises. 6. Steam leaks from the steam trap or condensate is not discharged.

Major causes for the above problems are usage under non-specified conditions (out

of specifications), insufficient pressure or flow rate, and clogs by dirt and scale.

Problem Symptom Cause Remedy

The secondary

pressure does

not rise

The PN-COS-16

body is not warm

No steam is being

supplied or the valve at

the primary side is closed

Check the primary piping

and valves

The body is warm,

but the pressure

does not increase

The strainer at the primary

side or the separator

screens is clogged

Clean or blow down

No motive air is being

supplied

Check the motive air

supply line

The secondary

pressure cannot

be adjusted or

increases

abnormally

Adjustment is

difficult, and set

pressure varies

The pilot screen is clogged Clean

The flow rate is too low Check the flow rate; check

the model selection,

replace with a unit that has

a smaller nominal diameter

or a more suitable unit if

necessary

The piston is clogged with

dirt

Clean

Check the piston ring



24


The secondary

pressure cannot

be adjusted or

increases

abnormally

Adjustment is

difficult, and set

pressure varies

The piston rings are worn Replace with new piston

rings

The small hole in the

piston is clogged

Clean

There is a build-up of dirt

on the sliding surfaces of

the pilot valve, piston or

main valve

Clean

The setting for the motive

air is inappropriate

Check the motive air

supply line; check the set

pressure

Flow rate exceeds rated

flow rate

Check the flow rate,

replace with a larger size

The adjustment screw has

seized

Replace with a new

adjustment screw

The diaphragm is

distorted or damaged

Replace with a new

diaphragm

There is fluctuation in

steam consumption

Check the flow rate;

replace the PN-COS-16 if

necessary

The PN-COS-16 is

inappropriate for the

service conditions

(specifications)

Check the model

selection, replace the PN-

COS-16 if necessary

Upon closing the

valves on the

secondary side,

the secondary

pressure abruptly

rises as high as the

primary pressure

The bypass valve is

leaking

Check, clean, and replace

with a new bypass valve if

necessary

There is a build-up of dirt

on or damage to the pilot

valve seat or main valve

seat

Clean

Align

Replace if necessary

Hunting or

chattering occurs

Occurs at low

steam demand

It is being used below the

minimum adjustable flow

rate

Replace with a smaller

size

Hunting never stops There is too high a

reduction ratio (operated

at below 10% of the

primary pressure)

Use two-stage reduction

The PN-COS-16 is


service conditions

(specifications)

Check the model


COS-16 if necessary

Chattering never

stops

Condensate is contained,

or the trap is blocked

Check the trap

Check the piping

The PN-COS-16 is


service conditions

(specifications)

Check the model


COS-16 if necessary



25


Abnormal noises Makes a high-

pitched noise There is too high a

reduction ratio, the flow is

too great, or there is a

high-speed open/close

valve nearby

Use two-stage reduction

Check the flow rate, use a

larger size

Install the valve as far

away as possible

Faulty steam

trap

Steam is blowing There is a build-up of dirt

on the trap valve seat or

at the float base

Clean

The body is installed tilted Check the piping

The float is deformed Check for water hammer

Replace with a new float

There is vibration in the

piping

Secure the piping

No condensate is

discharged

The primary pressure

exceeds the trap valve

seat maximum operating

pressure

Adjust the primary

pressure

Water is inside the float Replace with a new float

The secondary piping is

clogged

Check the piping

Clean

The trap valve seat is

clogged

Clean

Replace with a new trap

valve seat


26

TLV EXPRESS LIMITED WARRANTY Subject to the limitations set forth below, TLV Corporation, a North Carolina corporation

(“TLV”) warrants that products which are sold by it, TLV CO., LTD., a Japanese

corporation (“TLVJ”) or TLV International, Inc., a Japanese corporation (“TII”), (hereinafter

the “Products”) are designed and manufactured by TLVJ, conform to the specifications

published by TLV for the corresponding part numbers (the “Specifications”) and are free

from defective workmanship and materials. With regard to products or components

manufactured by unrelated third parties (the “Components”), TLV provides no warranty

other than the warranty from the third party manufacturer(s), if any.

Exceptions to Warranty

This warranty does not cover defects or failures caused by:

1. improper shipping, installation, use, handling, etc., by other than TLV or service

representatives authorized by TLV; or

2. dirt, scale or rust, etc.; or

3. improper disassembly and reassembly, or inadequate inspection and

maintenance by other than TLV or service representatives authorized by TLV; or

4. disasters or forces of nature or Acts of God; or

5. abuse, abnormal use, accidents or any other cause beyond the control of TLV; or

6. improper storage, maintenance or repair; or

7. operation of the Products not in accordance with instructions issued with the

Products or with accepted industry practices; or

8. use for a purpose or in a manner for which the Products were not intended; or

9. use of the Products in a manner inconsistent with the Specifications; or

10. use of the Products with Hazardous Fluids (fluids other than steam, air, water,

nitrogen, carbon dioxide and inert gases (helium, neon, argon, krypton, xenon

and radon)); or

11. failure to follow the instructions contained in the TLV Instruction Manual for the

Product.

Duration of Warranty

This warranty is effective for a period of the earlier of: (i) three (3) years after delivery of

Products to the first end user in the case of sealed SST-Series Products for use in

steam pressure service up to 650 psig; (ii) two (2) years after delivery of Products to the

first end user in the case of PowerTrap® units; or (iii) one (1) year after delivery of

Products to the first end user in the case of all other Products. Notwithstanding the

foregoing, asserting a claim under this warranty must be brought by the earlier of one of

the foregoing periods, as applicable, or within five (5) years after the date of delivery to

the initial buyer if not sold initially to the first end user.

ANY IMPLIED WARRANTIES NOT NEGATED HEREBY WHICH MAY ARISE BY OPERATION

OF LAW, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE AND ANY EXPRESS WARRANTIES NOT NEGATED

HEREBY, ARE GIVEN SOLELY TO THE INITIAL BUYER AND ARE LIMITED IN DURATION TO

ONE (1) YEAR FROM THE DATE OF SHIPMENT BY TLV.

Exclusive Remedy

THE EXCLUSIVE REMEDY UNDER THIS WARRANTY, UNDER ANY EXPRESS WARRANTY

OR UNDER ANY IMPLIED WARRANTIES NOT NEGATED HEREBY (INCLUDING THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE), IS REPLACEMENT; PROVIDED: (a) THE CLAIMED DEFECT IS REPORTED TO

TLV IN WRITING WITHIN THE APPLICABLE WARRANTY PERIOD, INCLUDING A DETAILED

WRITTEN DESCRIPTION OF THE CLAIMED DEFECT AND HOW AND WHEN THE CLAIMED


27

DEFECTIVE PRODUCT WAS USED; AND (b) THE CLAIMED DEFECTIVE PRODUCT AND A

COPY OF THE PURCHASE INVOICE IS RETURNED TO TLV, FREIGHT AND

TRANSPORTATION COSTS PREPAID, UNDER A RETURN MATERIAL AUTHORIZATION

AND TRACKING NUMBER ISSUED BY TLV. ALL LABOR COSTS, SHIPPING COSTS, AND

TRANSPORTATION COSTS ASSOCIATED WITH THE RETURN OR REPLACEMENT OF THE

CLAIMED DEFECTIVE PRODUCT ARE SOLELY THE RESPONSIBILITY OF BUYER OR THE

FIRST END USER. TLV RESERVES THE RIGHT TO INSPECT ON THE FIRST END USER’S

SITE ANY PRODUCTS CLAIMED TO BE DEFECTIVE BEFORE ISSUING A RETURN

MATERIAL AUTHORIZATION. SHOULD SUCH INSPECTION REVEAL, IN TLV’S

REASONABLE DISCRETION, THAT THE CLAIMED DEFECT IS NOT COVERED BY THIS

WARRANTY, THE PARTY ASSERTING THIS WARRANTY SHALL PAY TLV FOR THE TIME

AND EXPENSES RELATED TO SUCH ON-SITE INSPECTION.

Exclusion of Consequential and Incidental Damages

IT IS SPECIFICALLY ACKNOWLEDGED THAT THIS WARRANTY, ANY OTHER EXPRESS

WARRANTY NOT NEGATED HEREBY, AND ANY IMPLIED WARRANTY NOT NEGATED

HEREBY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE, DO NOT COVER, AND NEITHER TLV, TII NOR TLVJ WILL

IN ANY EVENT BE LIABLE FOR, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING,

BUT NOT LIMITED TO LOST PROFITS, THE COST OF DISASSEMBLY AND SHIPMENT OF

THE DEFECTIVE PRODUCT, INJURY TO OTHER PROPERTY, DAMAGE TO BUYER’S OR

THE FIRST END USER’S PRODUCT, DAMAGE TO BUYER’S OR THE FIRST END USER’S

PROCESSES, LOSS OF USE, OR OTHER COMMERCIAL LOSSES. WHERE, DUE TO

OPERATION OF LAW, CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER THIS

WARRANTY, UNDER ANY OTHER EXPRESS WARRANTY NOT NEGATED HEREBY OR

UNDER ANY IMPLIED WARRANTY NOT NEGATED HEREBY (INCLUDING THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE)

CANNOT BE EXCLUDED, SUCH DAMAGES ARE EXPRESSLY LIMITED IN AMOUNT TO THE

PURCHASE PRICE OF THE DEFECTIVE PRODUCT. THIS EXCLUSION OF

CONSEQUENTIAL AND INCIDENTAL DAMAGES, AND THE PROVISION OF THIS

WARRANTY LIMITING REMEDIES HEREUNDER TO REPLACEMENT, ARE INDEPENDENT

PROVISIONS, AND ANY DETERMINATION THAT THE LIMITATION OF REMEDIES FAILS OF

ITS ESSENTIAL PURPOSE OR ANY OTHER DETERMINATION THAT EITHER OF THE

ABOVE REMEDIES IS UNENFORCEABLE, SHALL NOT BE CONSTRUED TO MAKE THE

OTHER PROVISIONS UNENFORCEABLE.

Exclusion of Other Warranties

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND

ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,

ARE EXPRESSLY DISCLAIMED.

Severability

Any provision of this warranty which is invalid, prohibited or unenforceable in any

jurisdiction shall, as to such jurisdiction, be ineffective to the extent of such invalidity,

prohibition or unenforceability without invalidating the remaining provisions hereof,

and any such invalidity, prohibition or unenforceability in any such jurisdiction shall not

invalidate or render unenforceable such provision in any other jurisdiction.

13901 South Lakes Drive, Charlotte, NC 28273-6790, U.S.A.

Tel: [1]-704-597-9070 Fax: [1]-704-583-1610

Download - Pneumatic Control Valve for Steam COSPECT PN-COS-16

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